IS 8189 : 1996 ( Reaffirmed 2012 ) RUBBER HOSE FOR ON-SHORE OIL SUCTION AND DISCHARGE SERVICES SPECIFICATION (First Revision) ICS 23.040.70 0 BIS 1996 BUREAU OF INDIAN MANAK BHAVAN, 9 BAHADUR NEW DELHI h4ay 1996 STANDARDS SHAH 110002 ZAFAR MARG Price Group 3 Rubber Products Sectional Committee, PCD 13 FOREWORD This Indian Standard (First Revision) was first published in 1976 taking assistance from corresponding ISO/R 1823 : 1970 `Rubber hoses for oil suction and discharge' and British Standard 1435 : 1968 `Specification for rubber hose, wire-reinforced, for oil suction and discharge services'. In the light of experience gain over the years, this standard is being revised. In the present revision, requirements for 63 mm of hose for 0.7 and 1.0 MN/m2 maximum working pressure has been added. In addition Amendment No. 1 issued to earlier standard has also been incorporated. This standard covers the requirements for hoses used in dock and offshore operations. road and rail tankers will be covered by a separate specification. In Annex A given recommendations enhance the life of the hose. are for use, handling andstorage Hoses used in of hoses, which if followed, would This standard contains 5.3.2 and 7.1 which call for agreement between the purchaser and the supplier. For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with IS 2 : 1960 `Rules for rounding off numerical values (revised)`. The number of significant places retained in the rounded off value should be the same as that of the specified value in this standard. IS 8189:1996 Indian Standard RUBBER HOSE FOR ON-SHORE -OIL SUCTION AND DISCHARGE SERVICES SPECIFICATION (First Revision) 1 SCOPE This standard prescribes the requirements and the methods of sampling and test for rubber hose for on-shore oil suction and discharge hoses having smooth and abrasion-resisting outer covers, for use with all grades of petroleum and blended products having an aromatic hydrocarbon content not more than 25 percent. These hoses are for use~in dock and offshore operations and are suitable for use with -prOducES at temperatures from -20°C to + 80°C. 2 NORMATIYE REFERENCES The following standards contain provisions which, through reference in this text, constitute provision of this standard. At the time of publication, the editions indicated were valid. All standards are subject to revision, and parties to agreements-based on this standard are encouraged to investigate the possibility of applying the most recent editions of the standards indicated below: IS No. 7503 (Part 1) : 1988 443 : 1975 Title Glossary of terms used in rubber industry: Part 1 Definitions of basic terms (first revision) Methods of sampling and test for rubber hoses (second revision) 3 TERMINOLOGY 3.1 For the purpose of this standard, the definitions given in IS 7503 (Part 1) : 1988 shall apply. 4 MAXIMUM WORKING PRESSURE 4.1 The hoses shall be manufactured for use at maximum working pressures of 0.7, 1.0 and 1.5 MN/ma. 5 REQUIREMENTS 5.1 Material ELI.1 Lining and Cover 5.1.1.1 The lining shall be made from a suitable rubber compound resistant to all grades of petroleum and blended products having an aromatic hydrocarbon content not more than 25 percent. 5.1.1.2 The cover shall be made from an oil and weather-resistant rubber compound. 5.1.1.3 The lining and the cover shall also comply with the requirements given in Table 1. Table 1 requirements For Lining And Cover (Clnuse 5.1.1.3) Sl ("1' i) Characlerislic (2) I Requirement ' Lining (3) c4nJer ' (4) Method of Test Ref lo Cl No. (5) ii) iii) Tensile strength, MN/m', Mirl Elongation at break, percent, Mitt Swelling in fuel, percent by mass, Ma I 250 -30 7 300 loo 5 of IS 443 5 of IS 443 : 1975 : 1975 11 of IS 443 : 1975 iv) *Fuel soluble matter, percent by mass, Mar * Applicable only to suction hoses used for aircraft fuels. 3 - using a mixture of toluene and k-octane in the ratio of 30 : 7O(v/v) for 48 hours at room temperature. AnnexB + 1 MN/m2 = 10.2 kg/cm2 approximately. 1 IS 8189 : 1996 5.1.1.4 Accelerated ageing After ageing at 100 + 1°C for a period of 72 hours according to the method prescribed in 6 of IS 443 : 1975, the rubbers used for the lining and the cover, when tested according to the method prescribed in 5 of IS 443 : 1975, shall not vary by more than Z!Z 25 percent for tensile strength and $ percent ~forelongation at breakof the correspondingvalues obtained before ageing. 5.1.2 Reinforcement The reinforcement shall consist of natural or manmade fibre woven fabric, or a combination of these two, and steel wire helix. 5.1.2.1 Wire Thewire used for the helical reinforcement galvanized steel wire. 5.2 Dimensions 5.2.1 Bore The nominal bore when measured in accordance with the method given in 4.2.1 of IS 443:1975 shall be as given in Table 2. fit the threaded flanges. The threads shall be as agreed to between the purchaser and the supplier. 5.3.3 The nipples shall be so constructed as to provide good anchorage for the hose ends. This shall be done by welding or brazing to them circumferential bends of the same material as the nipples. The exterior of the hose over the nipples shall~taper smoothly into the body of the hose and shall be without any outside bands or clips. The length of the nipples outside the hose shall be as given in Table 3. Table 3 Projection of End-connections SI No. Nominol Bore of Hose Pro ection lo End of Nipple &Mar' shall be (1) 9 ii) iii) iv) v) 4 vii) mm (2) 63 75 100 150 200 250 300 mm (3) 115 130 150 150 165 180 180 mm (4) 135 150 180 180 190 200 200 5.4 Electrical Bonding Each length of the hose shall be electrically bonded between the nipples. This shall be done by bonding the nipples to the buit-in wire. Braided copper wire with minimum 9strands may be secured by brazing, soldering or welding one end with the embedded helical wire and the other end with the nipple. The bonding shall satisfy the requirements of 6.1.3. 5.5 Construction 5.5.1 Hoses Having Rough Bore The hoses having rough bore shall be constructed with the materials in the following order: 4 Internal wire helix connected to the nipples by welding or brazing, Ply of a textile fabric impregnated with oilb) resistant rubber, 4 Oil-resistant rubber lining, 4 Plies of textile fabric impregnated with oilresistant rubber, Cl Embedded wire helix spiralled over the nipples to a point beyond a second band and finished off with at least two close turns anchored together by soldering or welding, 9 Oil-resistant rubber filler, g) Plies of textile fabric thoroughly impregnated with oil-resistant rubber, and h) Smooth cover resistant to ageing and abrasion. 5.5.2 Doses Having Smooth Bore The hoses having smooth bore shall be constructed Table 2 Nominal Bore of Dose -SI ; Muximum Working Pressure (21 MN/u? Nominul Bore (3) mm 63,75,100,150 and 200 63,75,100,150,200,250 and 300 150,200.250 and 300 9 0.7 ii) iii) 1.0 1.5 5.2.2 Length Hose length shall be measured from face to face of flanges, and when supplied with nipples, from end to end of nipples. For hoses upto 100 mm bore the maximum length shall be 15 metres. For hoses of bore above 100 mm but up to 200 mm the maximum length shall be 9 metres and for hoses above 200 mm bore the maximum length shall be 7.5 mctres. 5.2.2.1 Tolerance on Length The actual length of the finished hose as defined in 5.2.2 shall not differ from the nominal length of the hose by more than zf percent. For this purpose the hose shall be measured before being subjected to hydrostatic test. 5.3 End Connections 5.3.1 The hose shall have built-in nipples. 5.3.2 The flanges shall he attached-to the nipples by welding or the nipples shall be threaded so as to 2 with the materials in the following order: IS 8189 : 1996 a) Inner tube or lining of oil-resistant rubber, b) Ply or plies of textile fabric impreganted with oil-resistant rubber, Cl Embedded wire helix spiralled over the nipples to a point beyond a second band and finished off with at least two close turns anchored together by soldering or welding, d) Oil-resistant rubber filler, e) One or more plies of textile fabric impregnated with oil-resistant rubber, and t) A smooth cover resistant to ageing and abrasion. 5.5.3 Joining of Wires Constructional helical reinforcement wires may be joinedby welding provided that: a) There shall be no joint in the internal wire helix, b) The welding of wires shall be carried out by using electrical butt welding method, Cl No weld shall be within 1.5m of a nipple end in the hose or of another weld in the same wire, and d) The number of welds shall not exceed one in a hose up to 6 m in length and shall not exceed two in a hose above 6 m in length. 5.6 Mass The maximum mass of the hose shall be as given in Table 4. 6 TESTS a) Lay out the hose as straight as possible. b) Fillwithwater,venting to remove all air, and C) d) e) 9 !a h) j) apply a pressure of 0.07 MN/m2. Measure the overall length of the hose assembly. Increase the pressure over a period of 5 minutes, from 0.07 MN/m2 to half the maximum working pressure marked on the hose. Hold this pressure for 10 minutes, then reduce the pressure over a period of 5 minutes to zero. Raise the pressure over a period of 5 minutes up to the maximum working pressure and hold for 10 minutes. Before releasing the full working pressure, measure the overall length of the hose assembly to asqertain the temporary elongation and record the increase as percentage of the original length measured at 0.07 MN/m2. Reduce the pressure over a period of 5 minutes to zero. After an interval of at least 15 minutes raise the pressure again to 0.07 MN/m2. Measure the overall length of the hose assembly to ascertain the permanent elongation and record the increase as a percentage of the original length measured at 0.07 MN/m2. 6.1.2 Elongation When tested in accordance with 6.1.1 the temporary elongation shall not exceed 10 percent for the hose of maximum workingpressure 0.7 MN/m* and 7.5 percent for the hoses of maximum working pressure 1.0 MN/m' and 1.5 MN/m*. The permanent elongation shall not exceed 2.5 percent and 1.5 percent in the above two cases respectively. 6.1 Tests on Finished Hoses Each hose shall be subjected to the tests given in 6.1.1 to 6.1.3. 6.1.1 Hydrostatic Test The hose shall~notshow any sign of failure or defect when tested as follows: Table 4 Maximum Mass of Hose (C/ause 5.6) Sl No. Nominal Bore I Maximum Working Pressure 0.7 MN/m2 kallghSmmth7bore (1) i) ii) iii) iv) v) vi) vii) (2) mm 63 7.5 100 150 200 250 300 (3) kg/m 8.5 10.0 15.0 30.0 45.0 Maximum Mass A Maximum Working Pressure 1.0 MN/m2 Maximum Working Pressure 1.5 MN/m2 Rough bore (7) kg/m 48.0 63.0 78.0 93.0 Smboth bore (8) kg/m 31.5 43.5 66.0 80.0 \ bore (4) ktim 6.5 7.5 11.0 22.5 28.5 A bore (5) kg/m 10.5 12.0 18.0 36.0 51.0 66.0 81.0 bore (6) kg/m 8.5 10.0 14.0 24.0 36.0 49.5 66.0 3 IS 8189 : 1996 6.1.3 Electrical Continuity Electrical continuity shall remain maintained between the nipples of each length of hose during and after subjection to hydrostatic test. The continuity shall be ascertained by using a 4.5 Volt battery and a 4 Volt, 0.3 Ampere test lamp. A dimly lighted lamp is sufficient to indicate a satisfactory electric continuity. 6.2 Test on Production Sample 6.2.1 The test shall be carried out as follows: Stage 2 - The hose shall be bent to the appropriate radius specified in Table 5. While in bent position, the test specified in 6.1.1 (b), (d) and (e) shall be repeated. Stage 3 - The hose shall then be released from the bent position and a pressure four times the maximum working pressure in'case of ordinary dock and offshore hoses and five times the working pressure in case of offshore marine hoses shall be applied. This pressure_shall be attained over a period of 15 minutes without failure of any kind. The pressure shall then be raised until the hose fails and the pressure at which it fails shall be recorded. Stage 1 - The hydrostatic test shall be carried out as given in 6.1.1. Table 5 Rend Radius Sl No. Nominal Bore Maximum Mass A Maximum Working Pressure 1.0 MN/m2 `Rough Smooth7 bore (5) m 0.85 1.00 I.25 1.85 2.50 3.10 3.70 (6) m 0.70 0.85 1.00 1.60 2.15 2.70 3.30 Maximum Working Pressure 1.5 MN/m2 Smooth ' `Rough bore bore (7) m 2.15 3.10 3.70 4.00 (8) m 2.00 2.80 3.40 4.00 \ r Maximum Working Pressure 0.7 MN/m2 Smooth' ' Rough bore (1) 9 ii) iii) iv) v) vi) vii) (2) mm 63 75 100 150 200 250 300 (3) m 0.75 0.85 1.10 1.60 2.15 - (4) m 0.65 0.70 1.00 1.40 1.85 - - - 6.2.2 Unless a production sample test is specifically r.equested by the purchaser, the manufacturer shall supply a certificate that a production sample test on a hose representative of current manufacture of the hose in question has been carried out in accordance with this standard. a) b) c) d) The manufacturer's name and trade-mark, if any; The hose denomination, type of bore and maximum working pressure; The factory test pressure; and The month and year of manufacture. 7 PACKING AND MARKING 7.1 Packing 7.3 IRS Certitication Marking 7.3.1 Each length of the hose may also be marked with the Certification Mark. The hoses shall be packed as agreed to between the Purchaser and the SuPPlier- However the following precautions shall be observed during packing and transportation: a) The hoses may be suitably wrapped in hessian over their entire length. They may be crated if desired. Flanged ends shall be protected by circular disks slightly greater than the diameter of the flange, bolted in two places diametrically opposite. The hoses shall be laid straight and supported evenly on carrier. Lifting points shall be clearly marked on the package to show permitted point for handling. 7.3.2 The use of BIS certification mark is governed by t h e provision of Bureau of Indian Standards Act, 1986 and Rules and Regulations made thereunder. The details of conditions under which the licence for the use of Standard Mark may be granted to manufacturers or producers may be obtained from the Bureau of Indian Standards. 8 SAMPLING 8.1IsThe of 443. sampling 19,5 shall be done according to 3 b) 7.2 Marking Each length of the hose shall be indelibly marked adjacent to each end with: 4 8.2 For the purpose of ascertaining conformity of a lot in a consignment, each length shall be subjected to visual inspection, length measurement, and hydrostatic, elongation and electrical continuity tests. All other requirements shall be tested on production sample. IS 8189 : 1996 ANNEX A ( Foreword ) RECOMMENDATIONS FOR USE, HANDLING AND STORAGE OF-HOSES The following recommendations are useful in obtaining maximum service from the hoses. The usershould, therefore, give utmost thought to these recommendations: a) The hoses should be regularly flushed with water after use. b) The hoses should be laid out straight on solid supports. Light weight hoses should be laid out in such a way that they are not subject to flattening. cl The hoses should be covered to protect them from sunlight. A cool, dark, dry storage place is preferred. d) The oldest hose according to the month and year of manufacture should be issued first. Before returning a hose to storage after use, it should be completely drained. f) The hoses used in white oil or crude oil should be flushed to remove any potential explosive vapours and stored in such a way that air can circulate freely through them. g) Condition of~hoses should be determined by frequent internal and external inspections and hydrostatic tests. h) Smooth-bore hoses should be looked into the ends for irregularities in the liner. Outside cover should be checked for serious defects or permanent deformation of the hose body. j) The hoses in service should be tested at least once every 6 months to the maximum working pressure and so kept for 5 minutes to examine the hose carefully for leaks at the nipples or anywhere else or for indication of weakness in the structure of the hose. k) Test records of each hose should be kept so as to compare the samewith theoriginal test results. ml The temporary elongation under test pressure of a hose in use should be exceed 1.5times the temporary elongation of the new hose. n) A hose should not be lifted from a single point with theends hanging down. The hose should be supported at least by two slings located near the reinforced ends, and if possible, a Bfting bar should be used. The hoses should not be dragged over docks or decks. They should be carried on dolleis or rollers or moved by derricks. A hose should not be rolled more than one revolution unless it is supported in such a way as to prevent the flanges from rolling faster than the hose and thereby twistingthe body of the hose. Lightweight hose should not be twisted or kinked. Sharp blends at nipples and end connections should be avoided. In use, a hose should be supported every 3 m by a belt sling. The hose should not be bent to a radius more than that recommended. `When disconnecting at the end of an operation, the hose should be drained, the flange faces protected with blank flanges and care taken that the hose is not dropped on the dock or the deck. The hose should not be allowed to liein pool of oil or other liquids which might affect the rubber compounds. Reciprocating pumps should be adjusted to reduce pulsation to the minimum. Relief valves should be set not to exceed 125 percent of the pressure rating of the hose. All valves should be checked before oil is admitted to the hose and care should be taken not to shut off the valves suddenly while the fluid is flowing. The hoses should be kept from chafing against the dock or any part of the ship. They should not be permitted to touch any hot surface. They should be closely watched during operation in order to avoid any undue stresses. PI 9) e> r) s) t) ANNEX B ( Table 1, Sl No. iv ) DETERMINATION OF FUEL SOLUBLE MATTER B-l PROCEDURE B-1.1 Cut the sample into pieces of size apProximately 3 X 3 mm. Extract 5 g of these Pieces 5 with 100 ml of a mixture of 30 parts by volume of pure toluene and 70 parts by volume of pure isooctane in a glass flask for 96 hours at 40 f 1°C adequate precautions being taken to prevent loss by evaporation. Filter fhe eontents, while still hot, B-2 CALCULATION into a hemispherical glass dish of suitable size, washing both the residue~in the~flask and that on Fuel soluble matter, percent by mass the filter paper with a ~further quantity of the sol= M2LM3X100 MI vent mixture. Evaporate the contents of the dish on a boiling water bath and heat the residue in a where ventilated air oven for 2 hours at 150 + 3°C. -Carry Mt = mass in g of the sample taken, out a blank determination on solvent mixture using M2 = mass in g of the residue left in the test the same volume as used in the test. with the sample, and NOTE?- If the determination of fuel soluble matter is made M3 = mass in g of the residue left in blank on a sample of lining taken from the hose, buff to remove any determination. adhering reinforcement fabric before cornminuting. 6 Bureau of Indian Standards BIS is a statutory institution established under the Bureau of Indian StandardsAct, IY86 to promote harmonious development of the activities of standardization, marking and quality certification of goods and attending to connected matters in the country. Copyright BIS has the copyright of all its publications. No part of these publications may be reproduced in any form without the prior permission in writing of BIS. This does not preclude the free use, in the course of implementing the standard, of necessary details,such as symbols and sizes, type or grade designations. Enquiries relating to copjrright be addressed to the Director (Publications), BIS. Review of Indian Standards Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewed periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue of `BIS Handbook' and `Standards Monthly Additions'. This Indian Standard has been developed from Dot : No. PCD 13 ( 1317 ), Amendments Issued Since Publication Amend No. Date of Issue Text Affected BUREAU OF INDIAN STANDARDS Headquarters: Manak Bhavan, 9 Bahadur Shah Zafar Marg, New Delhi 110002 Telephones : 323 0131,323 83 75,323 94 02 Regional Offices : Central : Manak Bhavan, 9 Bahadur Shah Zafar Marg Telegrams : Manaksanstha (Common to all offices) Telephone 323 76 17 1 323 38 41 37 84 99,37 85 61 37 86 26.37 9120 60 38 43 { 60 20 25 235 02 16,235 04 42 { 235 15 19,235 23 15 832 92 95,832-78 58 1 832 78 91,832 78 92 NEW DELHI 110002 Eastern : l/14 C. I.T. Scheme VII M, V. I. P. Road, Maniktola CALCUTTA 700054 Northern : SC0 335-336, Sector 34-A, CHANDIGARH 160022 1 Southern : C. I. T. Campus, IV Cross Road, MADRAS 600113 Western : Manakalaya, E9 MIDC, Marol, Andheri (East) MUMBAI 400093 Branches : AHMADABAD. BHUBANESHWAR. BANGALORE. BHOPAL. COIMBATORE. FARIDABAD. GHAZIABAD. GUWAHATI. HYDERABAD. JAIPUR. KANPUR. LUCKNOW. PATNA. THIRUVANANTHAPURAM. Printed at Pnntogmph. New Delhi. Ph 5726847